Apparatus for package molding, roofing asphalt

ABSTRACT

Roofing asphalt packaged in a film of polyester resin and the packaging method wherein hot asphalt is poured into a mold or boat that is lined by the polyester film at a charging station, such boat being floated on a stream of cooling water that carries the boat and its cooling contents to a discharge station whereat the cooled asphalt enveloped in the resin film is removed from the boat as the packaged product with the boat being returned to the charging station for reuse.

Waited States Patent 11 1 Parker 1Sept. 24, 1974 [5 APPARATUS FORPACKAGE MOLDING, 2,664,592 1/1954 Ingrahum C121] 1. 425/447 ROOFINGASPHALT 3,166,025 1/1965 Hulse 425/447 X 3,528,143 9/1970 Beneke 425/26lX Inventor: Reid Parker, 1347 3,680,991 8/1972 Cate et al. 425/86Washington, Wichita, Kans. 67211 3,763,661 10/1973 Betschart et al425/261 X [22] Flled' 1972 Primary ExaminerRobert L. Spicer, Jr. PP317,533 Attorney, Agent, or Firm-Robert E. Breidenthal 52 us. 01425/256, 425/117, 425/261, [57] ABSTRACT 425/447, 425/449 425/45553/122, 206/34 Roofing asphalt packaged in a film of polyester resin[51] Int. Cl. B29c 5/00 and the p g g ethod herein hot asphalt is [58]Field of Search 425/256, 261, 447, 86, poured into a m or at that islined by the polyes- 425/455, 117, 449, 455; 53/122, 214, 302, ter filmat a charging station, such boat'being floated 198, 61 on a stream ofcooling water that carries the boat and its cooling contents to adischarge station whereat the [56] References Cit d cooled asphaltenveloped in the resin film is removed UNITED STATES PATENTS from theboat as the packaged product with the boat 1,297,917 3/1919 Schmitt425/261 x bemg returned to the chargmg anon l reuse 2,167,392 7/1939McDonald 20 Claims, 20 Drawing Figures Pmmmww I 3.831.178

sew NF 8 PAIENIEB 89241974 smears 1: w) n M n m) ll fr: liii w f Z a S vu 7 uu "11 Ill L 6 i1 6 a l /1)\/C 2 PAIENTEBsmmu v amen g APPARATUS FORPACKAGE MOLDING, ROOFING ASPHALT The present invention relates to newand useful improvements in packages and in new and useful improvementsin methods of and apparatus for packaging materials, especiallymaterials having cohesive or tacky characteristics and/or cold-flowingcharacteristics.

More particularly the invention pertains to an improved packaged roofingasphalt wherein the asphalt is enveloped in a film of thermoplasticresin such that the package is (l) of sufficient strength and toughnessto maintain substantial dimensional integrity of package blocks ofapproximately rectangular configuration when stacked at temperaturessuch as normally prevail in where the same may be housed, or ontransport vehicles, (2) of such surface character as to preventcontacting packages from sticking to each other as would make otherwiseconvenient manhandling extremely difficult if not impossible, and (3)the resin envelope will soften or disintegrate to such an extent as tobe completely incorporated into the mass of the asphalt upon melting ofthe latter with no deleterious effect on the asphalt; this with noincrease of fire hazard or formation of scum at the temperatures towhich roofing asphalt is normally heated prior to application on a roof.

The invention also pertains to new and useful improvements in methods ofcooling asphalt as it is molded into packaged form and moved to alocation for expelling the enveloped and molded asphalt.

The invention also pertains to new and useful improvements in apparatusfor packaging goods possessing some if not all the difficult handlingand packaging characteristics as roofing asphalt, and especially for usein carrying out the improved packaging methods alluded to in thepreceding paragraph.

Prior art suggestions for packaging materials possessive of at leastsome of the difficult properties of roofing asphalt are set forth in thefollowing U.S. patents and the same can be referred to for a backgroundunderstanding of the art:

U.S. Pat. No. 3,366,233, entitled Packaged Asphalt, issued to J. C.Roediger, Jan. 30, 1968, and discloses asphalt being packaged in amultilayered or laminated container or encasement of sheeting or film ofpoly alpha olefin having a melt index below about 12 (measured at 230C.) and being composed of polyethylene,

polypropylene or the plastic or plastomeric copolymer of ethylene andpropylene. The sheeting or film ranges in thickness between about 2 andabout 6 mils.

U.S. Pat. No. 2,639,808, entitled Packaging of Tacky Materials, issuedto A. W. Barry et al., May 26, 1953, and discloses packaging tackymaterials in a flexible, solid film of a non-tacky, compatible materialand mentions films of such materials as polyethylene, ethylene/- vinylacetate interpolymers including polyesobutylene, polyvinyl ethers,polyvinyl esters, chlorenated polyethylene, soft aerylate andmethacrylate polymers, natural rubber, and synthetic rubber.Interestingly, this patent was assigned to E. I. du Pont de Nemours &Company which is a major manufacturer of polyesters such as used in thepractice of the instant invention, namely, a polyester (polyethyleneterephthalate resin) sold under the trademark MYLAR.

U.S. Pat. No. 2,762,504, issued Sept. 11, 1956 to W. J. Sparks et al.,and discloses, as set forth in the title,

Packaging Tacky Hydrocarbon Polymers in Polyethylene Film.

Other U.S. patents such as the following further show the state of theart:

U.S. Pat. No. 2,287,849 entitled Antistick Surface Coating;

U.S. Pat. No. 2,572,959, entitled Packaging Tacky Isobutylene-DiolefinRubber in Film of Compatible Styrene-Isobutylene Copolymer, which issuedto W. J. Sparks on Oct. 30, 1951;

U.S. Pat. No. 3,216,566, entitled Stabilizer- Lubricant Aggregate, whichissued to C. Rosenthal on Nov. 9, 1965.

A paramount object of the present invention is to envelope a mass oftacky and/or cold-flowing material such as roofing asphalt or the likein a film of non-tacky material that will substantially prevent coldflow and preclude enveloped masses of material sticking together, andwhich envelope film will soften, diffuse, disintegrate or readily mixinto and not adversely affect the material upon heating the latter to afluidity suitable for use.

Another paramount object is to provide a method that is suitable forenveloping roofing asphalt suitable for use on steep pitched roofs in athin film of a thermoplastic resin that softens at a temperaturesubstantially higher than that at which the roofing asphalt is normallypoured in conventional packaging, and which method is simple, economicaland can be practiced by persons with little special training without anyneed for complex or expensive machinery.

Another paramount object of the invention is to provide apparatus forpracticing the method of the preceding paragraph, and wherein cooling ofthe hot poured material is effected by heat exchange with water tha alsoserves to move the poured material.

The first major aspect of the invention involves the method of packaginga material having tacky and/or coldflowing characteristics, whichcomprises forming a pocket in a thin sheet of a thermoplastic resinhaving a melting point substantially higher than that of the material,softening said material to a flowable condition by heating the same, andflowing a quantity of the heated material into the pocket defined by thesheet of thermoplastic resin, such quantity being sufficient partiallyto fill the pocket, while exteriorly supporting and contacting the sheetof resin defining the pocket by a pocket forming member, and cooling thequantity of material in the pocket by withdrawing heat therefrom throughthe pocket defining sheet of resin and the pocket forming member.

The second major aspect of the invention involves, in packagingapparatus, the improvement comprising an elongated trough extendingbetween charging and discharging stations adopted to contain water, aboat or boatlike mold disposed in said trough and adapted to float onwater in the trough for movement between the stations, means at saidcharging station for depositing a quantity of the material to bepackaged into the boat when the latter is at the charging station, andmeans for moving the boat along the trough to the discharging station.

The third major aspect of the invention is the package or product and isa roofing asphalt derived from the refining of petroleum and having asoft point in the range of about F. to about 220 F. enveloped in a solidfilm of a polyester resin having a thickness less than about twothousandths of an inch to constitute packaged roofing asphalt suitablefor stacked storage and transportation.

Other objects, features, aspects and advantages of the invention willbecome apparent during the following description thereof, the same beinggiven in conjunction with the accompanying drawings, wherein:

FIG. 1 is an isometric view of roofing asphalt packaged in accordancewith the invention;

FIG. 2 is an isometric view of a boatlike mold lined with a film of athermoplastic resin and in condition for the pouring of hot asphalttherein;

FIG. 3 is a transverse vertical sectional view on a reduced scalethrough the arrangement of FIG. 2 after hot asphalt has been pouredthereinto;

FIG. 4 is an isometric view of packaged asphalt stacked on a cargopallet;

FIG. 5 is an isometric view on a greatly reduced scale of a conventionalcombined asphalt heater and trailer of the type wherein packaged asphaltcan be melted without envelope removal for roof application;

FIG. 6 is a broken isometric view of the trough array, the returntrough, and includes a diagrammatic illustration of the water collectingand storage tanks;

FIG. 7 is a fragmentary elevational end view taken from the discharge orunloading end of the trough array with parts being broken away and otherparts being shown in dashed outline to reveal hidden parts;

FIG. 8 is a fragmentary top plan view of the charging end of one of thetroughs and is taken from the plane of the line 8-8 in FIG. 7;

FIG. 9 is an elevational view of the asphalt heating furnace with partsbroken away;

FIG. 10 is a fragmentary end view of the trough supporting structure atthe mold return location and the inlet end of heated asphalt supplymanifold;

FIG. 11 is an enlarged transverse sectional view of the asphalt supplymanifold;

FIG. 12 is an enlarged fragmentary view taken from about the sameposition as the view of FIG. 10, and shows the filling of a mold at thecharging end of one of the troughs;

FIG. 13 is a schematic illustration of the water circulation and coolingarrangement;

FIG. 14 is an enlarged and fragmentary isometric view of troughs thatare in section along the plane of the section line 14-14 in FIG. 6;

FIG. 15 is an enlarged vertical sectional view taken upon the plane ofthe section line 15-15 in FIG. 6, with a pair of molds being shown insolid outline;

FIG. 16 is an enlarged vertical section taken upon the plane of thebroken section line l616 in FIG. 6;

FIG. 17 is a fragmentary elevational view taken upon the plane of theline 17l7 in FIG. 16, with parts of the L-shaped return trough beingbroken away;

FIG. I8 is an elevational view of the drain and settling tank with partsbroken away, and shows the same in relation to the return trough and thefeed and pump line to the water storage vessel;

FIG. 19 illustrates isometrically a manually grasped mold with envelopedasphalt therein; and,

FIG. 20 shows the enveloped asphalt dropped from a manually heldinverted mold.

Referring now to the drawings wherein like numerals designate like partsthroughout the various views, the reference numeral 10 designates apackage of generally rectangularly shaped block of roofing asphalt 12that is enveloped in a solid sheet or film of a polyester resin 14. Forconvenience in handling, storage, stacking, transport, and initialcooling in the desired shape, the package 10 weighs about 50 pounds, hasa length and width respectively of 24 inches and 12 inches. A height ofsomewhat less than 6 inches, namely, about 5% inches yields a packageweight of about 50 pounds. The length to width ratio of two to one makesstacking very simple, it being noted that a 24 by 24 inch configurationis obtained on two packages being laid side-by-side without regard towhether their major dimension is in one direction or at right anglesthereto.

While the substantially vertical corners, such as those shown at 16 and18, as well as the horizontal bottom side and end edges 20 and 22 arerounded somewhat, the top and bottom sides 24 and 26 of the package 10are essentially flat and horizontally parallel so as to be convenientlystacked such as upon a pallet designated generally at 28 in FIG. 4 fortransport by a fork lift truck or the like, not shown.

The asphalt contained or enveloped in the package 10 is essentially anasphaltic residue derived during the refining of petroleum and which ismarketed as roofing asphalt.

The roofing asphalt 12 is of a relatively high softening point ascompared to roofing asphalts suitable solely for use on dead flat roofs(that is, perfectly flat roofs or roofs sloping less than one-quarterinch per foot). The asphalt has a softening point preferably about 200F. to 205 F. and the soft point can be in the range of about F. to about220 F. The asphalt 12 is a roofing asphalt suitable for use on pitchedroofs.

Generally speaking, the roofing asphalts of this invention are such asto require heating to a temperature in excess of 240 F. and typically toabout 275 F. to about 325 F. in order to possess sufficient fluidity tobe readily piped and valved or to conduct the pouring done in packagingoperations; this notwithstanding the fact that roofing asphalt suitablefor pitched roofs has a softening or melting point in the range of about170 F. to 220 F. As with materials of amorphous character the meltingpoint is not sharply defined but is a temperature region called thesoftening or soft point at which the material appreciably loses theappearance and short term character of a solid, and becomes soft andreadily susceptible to deformation rather than fracture.

port wheels 34, and a frame tongue 36 having a tow hitch 38. A propstructure 40 is provided for selectively supporting the frame tongue 36as shown.

The heater has a vat, not shown, normally covered by a retractable hood42 and burner means, not shown, is provided for heating the contents ofthe vat, such burner means being fueled by fuel carried in a fuel tank44. If desired the burner means can be regulated by thermostaticallycontrol means, not shown, for main taining the contents of the vat at apredetermined temperature that is usually in or about the temperaturerange of about 440 F. to about 525 F.

In any event, the vat and the opening thereinto is adequate toaccommodate the introduction of a package dimensioned as aforesaid. Aswill be explained in greater detail hereinafter, the entire package 10inclusive of the enveloping film 14 is charged into the heating unit 30and there is no need or useful purpose in separating the film 14 fromthe asphalt, as the film is incorporated into the entire bulk or mass ofasphalt in the vat without any deleterious effect thereto.

If desired the package 10 can be broken into two or more parts byhammering the same or by subjecting the same to a sharp or high bendingmoment when at any temperature well below the softening or melting pointof the asphalt 12, so that an amount of less than 50 pounds of asphaltcan be charged to the heater 30 when desired, but here again there is noneed to separate the film 14 from the asphalt 12.

It should be noted that while the strength of the film 14 portion of thepackage 10 is sufiicient to prevent appreciable cold-flow of the asphalt12, it is not so strong as to prevent fracturing or break up of thepackage 10 as a catastrophic event on heavy hammering or the applicationof sharp or shock bending moments of high intensity. Thus the packages10 can maintain their integrity of configuration despite any cold-flowcharacteristics that the asphalt 12 may have, and they can also standnormal handling without breakage, and yet be such as to be breakableinto parts if desired at the site of use immediately prior to placementin the heater 30.

The characteristics of the package 10 described above are due to theabove described characteristics of the asphalt l2, and are in part dueto the dimensions of the package 10 previously given. Thecharacteristics of the package 10 are in great measure attributable tothe character of the film 14 and its thickness. The film 12 is athermoplastic resin of high strength, is non-tacky, has little or notendency to adhere to the inner surface of a boatlike mold 46 in whichthe package 10 is molded or formed, is completely compatible with theasphalt 12 and produces no detectable deleterious effect thereon (atleast in very low concentration), and has a softening or melting pointsubstantially above the highest temperature (about 325 F.) at which theasphalt 12 is poured into the mold 46, and is in the neighborhood orbelow the lowest temperature (about 440 F.) to which the asphalt 12 isheated in the heater 30 prior to roof application.

A polyester resin film of 0.0005 inch thickness marketed by D. I. duPont as its Type A polyester film under its trademark MYLAR isespecially well suited. The condensed Chemical Dictionary 5 EditionReinhold Publishing Co., 1956, states on page 746 that MYLAR is the duPont trademark for a highly durable, transparent film of polyethyleneterephthalate resin, characterized by its outstanding strength,electrical properties and chemical inertness. A publication of du Pontrelative to MYLAR states that Type A MYLAR has the followingcharacteristics and uses:

Characteristics A strong, tough polyester film with low electrical faultcount. Transparent in 50 and 100 gauges whereas the heavier gauges suchas 500 and above are translucent.

Electrical Uses Slot liners, wedges and phase insulation for motor andfield coils; insulation for magnet wire and as a barrier and insulationtape in cable construction; insulation between turns in transformercoils; backing for mica.

Non-Electrical Uses Base for magnetic recording tape and otherspeciality tapes; surfacing material for acoustical tile; industriallaminations with other flexible materials release sheet for reinforcedplastics, stationery supplies (in lighter gauges), engineeringreproduction materials; apparel stays; etc.

The above described Type A of polyester resin film (MYLAR) has asoftening or melting point far above 325 F. and is about 480 F. orbelow. This resin film softens and weakens at a temperature of 440 F. tosuch an extent that it disintegrates and simply is diffused or isabsorbed and mixes with the asphalt 12 about which it enveloped in apackage 10 when the temperature is raised to about 440 F.

Such polyester resin film 14 does not deleteriously effect the asphalt12 on being mixed with or incorporated into the mass of the latter. Theabove described polyester resin film 14 is also preferred because it hasvirtually no tendency to stick or adhere to the inner surface of the(polyethylene) mold 46 and because only a one-half mil thickness isadequately strong to prevent appreciable cold-flow of the describedpitched roof type roofing asphalt 12 in its package dimensions, and yetwill yield to shocks sufficient to fracture the asphalt 12.

Other polyester resin films having a softening point in the requisiterange (above about 375 F. to about 480F.) can be used and these as wellas the previously described resin can, of course, be of about one-halfmil thickness. Thicknesses of two mils or more can be used but tend tobe too strong to enable breaking a package 10 into smaller parts, atleast without substantially greater effort. Greater thickness alsobecomes relatively less economical, polyester resin films being fairlyexpensive by weight. Thicknesses of less than one-half mil may tend tolack sufficient strength, and for this reason and for the reason thatsubstantially thinner films are so light and are difficult to handle inmoving air that they are not recommended despite lower cost.

While other thermoplastic resins of proper physical properties may existand can be used, polyester resin films, such as marketed under thetrademark MYLAR, are the only films that have been found to besatisfactory in every respect and are far and away the most preferred ofall that have been tried. Specifically, polyethylene films and saranresins have been found decidedly unsatisfactory. The desired ornecessary physical properties have been set forth earlier and includebeing nontacky, strong, being thermoplastic and melting above about 375F. and preferably between 440 F. and 480 E., and being compatible withthe asphalt.

The present invention does not produce satisfactory results with respectto low soft point asphalts (such as suited only for dead level roofs) asthey are so fluid and cold fiow so readily as to require totallyimpractical thickness of film. Accordingly, the present invention onlyhas applicability to asphalts or physically similar materials which havelittle if any tendency to cold flow at temperatures to which thepackaged material will normally be subjected in storage or duringshipping.

This excludes the invention from practical applicability to roofingasphalts having a soft point lower than about F. as measured by standardtest procedures.

Such roofing asphalts cold flow to such a minor degree, if at all, atnormal storage and shipping temperatures that the resin film 14 canreadily when of about onehalf mil thickness accommodate, by reason ofits inherent resiliency or stretchability, the dimensional changes thatmight occur over a prolonged period of time. In actual tests thus farconducted, no package 10 in accordance with the invention has failed ina period of hot summer months and it is expected that few, if any atall, would fail in stacked storage, say, eight packages high, in over ayear.

The boatlike mold 42 can be of metal (aluminum or steel, for example)and lined or unlined by some surface coating such aspolytetraethylfiouride (as sold under the trademark TEFLON) for itsnon-tackyness and slippery nature; however, the mold 42 is subjected torough handling and deformative damage, and consequently, the presentinvention employs boatlike molds 46 made of high density polyethylene,it having been found that such molds 46 having wall thicknesses of about0.20 inch and greater are quite rugged, are not excessively expensive,do not readily adhere to polyester resin film, can be easily cleaned ofasphalt with a small quantity of kerosene or other readily availablesolvents, have substantial salvage value, and have an adequate thermalconductivity to cool asphalt therethrough at a reasonable rate.

The shape of the mold 46 will be readily appreciated from the drawings,the same including a flat bottom wall 48 that is integral withupstanding end walls 50 and upstanding side walls 52. The end walls 50as well as the side walls 52 diverge slightly upwardly to afford draftand to facilitate removal of the package 10 from the mold 46. Forreinforcement and in order to provide good handholds for manual handlingof the molds 46,

when filled as well as when empty, the upper peripheral margins of theend and side walls 50 and 52 are bent outwardly and thence turneddownwardly to define a continuous peripheral rim 54 about the top of themold 46 that is of an inverted U-shape in transverse section. Thehorizontal internal dimensions of the mold are 24 inches X12 inches. Theinternal height of the mold 46 is substantially more than the height ofthe product or package 10 of about inches and can conveniently be about6% inches so that the operator can quite accurately estimate visuallywhen the mold 46 has been filled to the proper depth, and yet run norisk of overfilling and also be sure of the buoyancy of the charged mold46. The mold 46 can be of greater height if desired or deemed efficient.A height of 6% inches assures that it is not necessary to entirely fillthe mold 46, and will assure buoyancy and stability (one could even saysea-worthiness) when the mold 46 with a package therein is floating onwater.

Attention is now directed to the apparatus whereby a package 10 ofenveloped asphalt is molded within a mold 46 and cooled.

Referring to PEG. 6, it will be seen that there is provided a pluralityof straight, elongated and parallel troughs, such as those indicated at60, 62, 64, 66, 68 and 70. Such plurality of troughs are substantiallyhorizontal and are such as to contain static water at substantial depthfrom end to end. The plurality of troughs 60, 62, 64, 66, 68 and 70 arearranged in a side-by-side relationship so as to constitute arectangular array thereof 72 having parallel opposite ends 74 and 76 andparallel opposite sides 78 and 80. The array 72 of troughs 60-70 areelevated above a floor or working surface 82 and are supported byperipheral masonry or concrete end walls 84 and side walls 86, and bytrans verse walls 88 connecting the side walls 86 at spaced positionsintermediate the end walls 84.

The character of the troughs 60, 62, 64, 66, 68 and can be bestappreciated upon reference to FIG. 14, wherein exemplary troughs 64, 66and 68 are shown in detail. As clearly depicted each of the troughs ismade of a single sheet of steel that is generally of channel-likeconfiguration and includes a flat central or bottom wall portion 90 thathas upturned side edges defining parallel, spaced vertical walls 92 and94 of equal height, and the upper edges of the walls are bent outwardlyat 96 and 98, respectively, and thence upwardly at 100 and 102 to defineoppositely extending horizontal shoulders 104 and 106 of equal heightand horizontal extent and upstanding vertical and parallel walls 108 and110. The outer faces of the walls 108 and 110 of adjacent troughs abuteach other, and the upper edge portion of the wall 108 is bent about toembrace the upper edge portion of the abutting wall 110 as plainlyillustrated at 112 in FIG. 14. Such arrangement prevents water fromentering between abutting walls 108 and 110 from above and facilitatesassembly of an array of troughs in close juxtaposed arrangement.Identity of the troughs enables prefabrication of troughs at arelatively low cost.

The opposite open ends of the troughs are conveniently closed by upwardextensions 114 of the end walls 84 in sealing relationship to theopposite ends of the assembled trough structures shown in FIG. 14.Similarly the side walls 86 are extended upwardly a sufficient amount toafford lateral support to the walls 108 and 110 of the troughs 60 and70.

The side walls 92 and 94 of the troughs have a spacing less than theoverall width of the mold 46, and greater than the spacing of the outersurfaces of the side walls 52 of the mold 46. The side walls 92 and 94have a height greater than that of the mold rim 54 above the bottom wall48 of the mold. The upper side wall portions 108 and 110 of the troughshave a greater spacing than the overall width of the mold 46 including,of course, its rim 54.

As thus far described each of the troughs 60, 62, 64, 66, 68 and 70 isadapted to contain water 116 of sufficient depth so as to float (seeFIG. 16) a mold 46 containing a package 10 with the bottom wall 48spaced above the bottom wall 68 of the trough in an arrangement that allsubmerged portions of the mold 46 are exteriorly surrounded by water.The arrangement is such that a charged mold 46 (by which is meant a moldinto which the asphalt l2 and film 14 to consitute a package 10 has beenplaced) can be floated from the charging end of each trough (the end ofthe trough at the end 74 of the trough array 72) to the discharge end ofsuch trough (the end of the trough at the end 76 of the trough array72). Indeed, not only can a charged mold 46 be floated the entire lengthof each trough 60, 62, 64, 66, 68 and 70, but a mold 46 is caused tomove in such trough within which it may be disposed from the chargingend thereof to the discharge end thereof by movement of water in thetrough from the charging end to the discharge end of the trough. As willbe seen shortly, water in the troughs not only supports or buoys up thecharged mold 46, but it also transports or moves the charged mold 46from the charging to the discharge end of the trough; and furthermore,will so supporting and transporting the charged mold 46, the water 114constitutes a heat exchange medium for cooling the charged mold 46, itbeing noted that the asphalt 12 is charged into the mold 46 at atemperature in excess of about 275 F. and must be cooled well below itssoftening or soft point which may be as low as 170 F.

A generally L-shaped water return trough designated generally at 120 hasone leg 122 mounted along the exterior 122 of the wall 84 at thedischarge end 76 of the array 72. The trough leg 122 is disposed belowthe top of the wall 84 and the troughs 60, 62, 64, 66, 68 and 70 areprovided with overflow weirs such as indicated at 124 in FIG. 16 in anarrangement whereby the water 116 in the troughs can overflow as at 126into the trough leg 122. The trough leg 122 has a closed upper end 128and slopes gently downwardly along the wall 84 to its juncture 130 withthe other leg 132 of the trough 120.

The leg 132 is mounted upon and extends along one of the walls 86 at theedge 80 of the array 72 and is sloped to deliver water received from theleg 122 to a position adjacent the charging end 74 of the array 72.

At the position 134 the return trough leg 132 opens into an oppositelyextending discharge trough 136 that is arranged to dump or dischargeinto a settling tank 138, wherein solid foreign matter that may be inthe water can settle out. Though not shown, the tank 138 can be disposedoutside of a building structure, not shown, that houses and shelters allthe structure thus far shown, excepting only a trough portion 140 at thedischarge end of the trough section 136 that can extend through anexterior building wall, not shown. Disposing the open topped settlingtank 138 exteriorly of any sheltering building facilitates the aircooling of water that will have become heated in the course of coolingmolded asphalt.

A water supply tank 142 is provided that is also preferably disposed forair cooling of its contents, such tank being at a height sufficient tosupply water by gravity flow to a water supply manifold 14 through awater line 146 connecting the tank to the manifold. A line 148 having awater pump 150 therein connects the settling tank 138 to the elevatedwater supply tank 142.

Referring now especially to FIG. 13, the water circulating and coolingsystem will be readily understood. The water supply tank 142 ismaintained at a predetermined leval by introduction of water thereintofrom water mains, water wells or the like, not shown, to the extent thatmake-up water is required. Water in the tank 142 is gravity fed by line146 to the water manifold 144, the latter extending along the chargingend of the troughs 60, 62, 64, 66, 68 and 70, with each of such troughshaving communication by individual valve controlled conduits 152 withthe manifold 144. Such valve controlled conduits are all identical toeach other and an appreciation of all can be had on reference to FIGS. 7and 8 wherein the valve controlled conduit 152 provided in associationwith the charging end of the trough 66 is clearly shown as comprising amanually controlled valve 154 tapped into the manifold 144 and connectedby an elbow 156 to an inclined pipe 158 that extends downwardly to aposition adjacent the bottom of the trough 66. The outlet end of thepipe 158 terminates in an elbow arranged to discharge water in adirection parallel to the major dimension of the trough 66 and towardsits discharge end.

The operator of the apparatus can individually control the rate of waterintroduction into and consequently the water flow rate in each trough.

Recapitulating, water from the tank 142 flows in the pipe 146 in thedirection indicated by the arrows 162 to the manifold 144, and flows inthe latter as indicated by the arrows 164 to the various distributormeans or valve controlled conduits 152.

Water thence flows in the various troughs of the array 72 as introducedtherein in the direction indicated by the arrows 166, and thence in thetrough as indicated by the arrows 168 to discharge gravitationally intothe settling tank 138 as indicated at 170. Water from the tank is thenpumped via the line 148 to its point of starting.

The L-shaped trough 120 and the juncture 131) of its legs are such thatempty molds 46 placed in the trough 120 at any position therealong iscarried or urged along such trough by the water movement 168 therein tothe position 134 that is in close proximity to the charging end 74 ofthe array 72 and to one end of an endless conveyor designated generallyat 180. The conveyor includes an upper flight 182 at a height about thesame as that of the trough array 72, and the conveyor 180 is parallelto, substantially coextensive with, adjacent to, and spaced from thecharging end of the array 72, and the upper flight 182 travels in thedirection indicated by the arrow 184. Such arrangement as will be seengreatly facilitates repetitious use of each mold 46.

During continuous operation of the equipment, it has been found that noproblem of water freezing has been encountered despite ambient airtemperatures that have ranged to as low as about 3 F. No water freezingproblems are anticipated under the climatic conditions of Kansas, forexample; however, the water tanks exposed to weather should be drainedduring shutdowns in cold weather. it is well within the realm ofordinary skill to avoidfreezing problems including the use of anantifreeze, or using salt brine instead of pure water (provided thetroughs and the tanks have adequate rust resistance or suitablecoatings).

A heated supply of asphalt is provided comprising an asphalt supply tank191) having an asphalt fill opening (not shown) normally closed by acover 192. The tank 191) has a false bottom 194 for containing theasphalt 196, and. a gas burner means 196 having a gas supply line 198 isdisposed in the tank'19t) below the false bottom 194 and the hotcombustion products of the burner means 196 via a plurality of fluetubes, not shown, disposed within the mass of asphalt 196 to the upperportion 2110 of the tank 191) for ultimate discharge from the tank 1% bya chimney 2112.

Hot asphalt 196 in the tank is moved via a discharge line 204 and pumpmeans 206 in the direction indicated by the arrows 208 to an asphaltsupply manifold 210.

The line 204 and the manifold 210 are both heavily insulated to avoidloss of heat, and in order to facilitate ease of starting both of suchconduits can be provided with heating means embedded in the heatinsulation thereof; however, such heating means is shown only inconjunction with the manifold, as those conversant with handlingasphalts and the like will understand that similar heating means can beprovided for the line 204.

The asphalt manifold 210 comprises (see FIGS. and 11) a steel pipe 212spaced above the charging end of the array 72 and supported by U-shapedbraces 213 welded thereto, it being understood that the braces 214 aredependingly supported by ceiling or roof structure, not shown. Welded toopposite sides of the pipe 212 are a pair of relatively small steelsteam pipes 216 and 218 through which steam under pressure is circulatedto heat the pipe 212 sufficiently to maintain the asphalt contentsthereof at a temperature on the order of about 275 F. to 325 F. forpouring or molding operations presently to be described.

The pipe 212 and the steam heater pipes 216 and 218 are embedded in orheavily encased in thermal insulation such as wrapped asbestos 220.

Conventional means for controlling the circulation, temperature andsupply of steam circulated in the pipes 216 and 218 is designatedgenerally at 222; and the character and operation of the same is wellknown.

The manifold 210 is provided with a plurality of individually (valve)controlled outlets 224; one each directly above each of the troughs 60,62, 64, 66, 68 and 70 in closely spaced relation to the charging endthereof. Each of the valve controlled outlets 224 comprises a downwardlydirected pipe 230 connected to the interior of the manifold pipe 212 andin which there is a valve having a wrench actuable valve control member232 whereby an operator can close the pipe 230 and open the same to anydesired degree. The arrangement is such that a mold 46 over which arectangular sheet of polyester resin 14 has been placed and pressed downin the mold 46 sufficient to establish a pocket therein can be floatedin water 60 in the trough at the charging end of the latter (see FIG.12) and the valve member 232 actuated to open the pipe 230 and to flowor pour asphalt as a stream 240 into the film lined mold until thelatter is filled the desired depth of about 5% inches. Prior to, duringor after the charging operation, water can be introduced into the troughto cause flow of water in such trough, overflow of water at thedischarge end of the trough, and to transport the charged mold 46 towardthe discharge end of the trough. While largely a matter of choice, it ispreferred to defer initiation of the introduction of water until themold 46 has been charged so as to avoid any premature movement of themold 46 prior to its having been fully charged.

As soon as the mold 46 has been charged, the free edge margins of thesheet or film 14 can be dressed down over the top of the asphalt thoughsuch dressing down can be deferred to any time prior to emptying themold 46. The film 14 is conveniently cut in rectangular or square formand with the mold 46 dimensioned as previously described canconveniently be about 48 by 48 inches. obviously, such size of filmsheet is far more than necessary to cover the exterior of the moldedasphalt 12; however, such excessive size is fully or in large measurewarranted by requiring far less care in centering a sheet over an emptymold and in pushing the center down in the mold to form a film pockettherein for reception of asphalt. Precise centering is not required,which would necessitate greater care and a greater expenditure of timepreparatory to charging or filling the mold, but additionally theoperator does not have to exercise relatively greater care in dressingdown the free upstanding marginal edges of the film over the top of thepoured asphalt in order to assure full coverage of all exposed surfacesof the asphalt. Indeed, rather lavish proportioning of the film enablesthe operator who pours the asphalt to immediately after the pouring todress down the free marginal edges of the film without incurring anyundue risk of burning his bare hands in the hot asphalt. All parts ofthe marginal edges of the film that contact the asphalt adhere thereto,and no detriment results in excess film area extending free.

The excessive film area not only facilitates the handling of the filmprior to and after the pouring of the asphalt, but also assures allexterior surfaces of the asphalt being covered and not only shelteredfrom surface contamination, but most importantly prevents the asphaltfrom contacting and adhering to other packages or other materials orstructures.

The operator can line or provide a mold 46 with the film 14 after hereceives the mold 46 on the conveyor 180 at the location of the troughto be used, or an assis tant can operatively associate a mold 46 and asheet or piece of film 14 at a position adjacent both the return trough(position 134) and the conveyor 180, and place such associated parts onthe conveyor for delivery to the location of the trough in which it isto be charged.

The movement of charged molds 46 in a trough as indicated by the arrows250 is not of positive character and such charged molds 46 can andnormally do pile up end-to-end against the discharge end of the trough.Water can, of course, continue to flow by such backed up charged molds46 and in flowing thereby continue to cool the exterior of the molds 46and, of course, the contents thereof.

In an actually working emboeiment of the above described apparatuswherein troughs of 100 feet length are used, it can typically take hoursfor a charged mold 46 to cool sufficiently for emptying. A singleoperator can quite easily completely fill a trough of 100 feet lengthlong before the earliest charged mold 46 is ready for discharge, and itis therefore desirable to provide more troughs than the number ofoperators that are to be employed; otherwise inconveniently long troughswould be required. In practice with 100 foot troughs, it has been foundthat the rate of cooling is typically such that one operator can makebeneficial use of eight or more troughs.

When a charged mold 46 at the discharge end of a trough has cooledsufficiently to be discharged, the film 14 will be dressed over thesurface of the asphalt if this has not already been done, and thengrasping the mold 46 by its rim 56 as shown in FIG. 19 lift the chargedmold 46 from the discharge end of the trough and then turn to his rearwhile inverting the mold 46 to drop its contents (see FIG. 20), namely,the package 10 upon a conveyor means 260 disposed at his rear. If thepackage 10 does not fall of its own weight, a minor degree of ingenuityon the part of the operator in the way of tapping the bottom of the moldor by dropping the same inverted on the conveyor means 260. Upon themold 46 being freed of its contents, the operator places the same,upright, of course, in the water return trough 122 for water urgedtransport to the position 134 for reuse of the mold 46 as previouslydescribed.

The conveyor means 260 is parallel to and is spaced from the dischargeend of the array 72 as clearly shown in FIG. 6. The conveyor means 260has an upper flight 262 that is about the same height as the trougharray 72, and the flight 262 can be arranged to travel in eitherdirection of its length to deliver all packages processed from all thetroughs to a common cargo handling point or automatic cargo handlingequipment, not shown.

The packages 10 preclude the waste of time and effort normally requiredat the site of a roofing job of removing packaged asphalt from itscontainers. Customary containers are unsuited for incorporation into theroofing asphalt itself.

A most beneficial result is in the nature of preserving our ecology andin minimizing land and air pollution. ln utilizing the packages 10,there is no residue or refuse in the nature of empty asphalt containersabout the roofing site to offend the eye, and no ill consequencesoccasioned by the burning of used container refuse such as smoke,odorous fumes or noxious combustion products. There is no need to haulsuch refuse away or to provide dumps or other remote disposal means.These benefits are even greater than the not inconsiderable expense ofthe wasted containers and the cost of attempting to dispose of the same.

Attention is now directed to the appended claims.

I claim:

1. ln packaging apparatus, the improvement comprising an elongatedtrough extending between charging and discharging stations adapted tocontain water, a boatlike mold disposed-in said trough and adapted tofloat on water in the trough for movement between the stations, means atsaid charging station for depositing a quantity of the material to bepackaged into the mold when the latter is at the charging station, andmeans for moving the mold along the trough to the discharging station.

2. The combination of claim 1, wherein said means for moving the moldcomprises means for moving water in the trough from the charging to thedischarging statron.

3. The combination of claim 2, wherein the means for moving the waterincludes means for receiving water from the trough adjacent thedischarge station and for delivering water so received to the troughadjacent the charging station.

4. The combination of claim 2, wherein said means for moving the waterincludes means for receiving water from the trough adjacent thedischarge station, and means inclusive of a pump for delivering water soreceived into the trough adjacent the charging end.

5. The combination of claim 4, including a second elongated troughhaving first and second portions that are respectively relating closerto the discharge and charging stations of the first mentioned trough,said second trough being sloped downwardly from the first to the secondportion thereof whereby water therein will flow from the first to thesecond portion thereof,

said first portion of the second trough being disposed at a height lessthan that of the first mentioned trough at the discharge station of thelatter, means for overflowing water in the first mentioned trough thatis above a predetermined depth at the discharge station into the firstportion of the second trough, and with said pump being disposed toreceive water from the second portion of the second trough in anarrangement such that the mold can be removed from the first mentionedtrough at the discharge station, and placed in the first portion of thesecond trough for water urged movement in the second trough to aposition in the second portion of the latter in closer proximity to thecharging station.

6. The combination of claim 5, including a conveyor for moving a moldfrom adjacent said position to a second position in relatively closerproximity to the charging station.

7. The combination of claim 3, wherein said means for receiving anddelivering water includes means for cooling the water prior to deliverythereof.

8. The combination of claim 3, including a water storage tank disposedat a height greater than the charging station, whereby water can bedelivered by gravity flow from the tank into the trough adjacent thecharging station of the latter, and a pump for pumping received waterinto the tank.

9. The combination of claim 3, wherein received water is placed indirect heat exchange relation with the atmosphere for cooling thereofprior to delivery into the trough.

10. The combination of claim 3, wherein received water is placed inindirect heat exchange relation with the atmosphere for cooling thereofprior to delivery into the trough.

1 ll. Asphalt packaging apparatus comprising a plurality of elongatedand generally parallel troughs disposed in a generally rectangular arraywith each trough having one end at one end of the array and its otherend at the other end of the array, means for introducing water into eachof the troughs at its said one end, means for removing water from theother ends of the troughs, a plurality of boatlike molds adapted tofloat in said troughs in heat exchange relation with water therein andto be moved by water movement therein from the one end to the other endof each trough, and means for pouring a quantity of hot asphalt intosaid molds when floating at said one end of each of said troughs.

12. The combination of claim 11, wherein the means for pouring includesan asphalt dispensing manifold extending along said one end of therectangular array, means for maintaining contents of the dispensingmanifold at an elevated temperature suitable for dispensing asphalttherefrom, said asphalt dispensing manifold having a valved outlet aboveeach of the troughs adja cent said one end of the troughs.

13. The combination of claim 11, wherein the means for introducing waterincludes a common water supply and each of said troughs havingindividually associated therewith a valve controlled means that iscoupled to a water supply.

14. The combination of claim 11, including an endless conveyor meansadjacent to and parallel to said one end of the rectangular array formoving molds from adjacent a corner of said array along a travel pathadjacent said one end of all the troughs.

15. The combination of claim M, including an endless conveyor adjacentto and parallel to the other end of the rectangular array for movingpackaged asphalt from adjacent said other ends of all the troughs towarda single cargo handling location.

16. The combination of claim 11, wherein the means for introducing waterand the means for removing water are operatively associated by means forreturning removed water to the water introducing means, whereby water isrecirculated through the troughs.

17. The combination of claim 16, wherein the means for returning waterincludes means for cooling the water.

18. The combination of claim 16, wherein the means for returning waterincludes an elongated generally L- shaped water return trough havingfirst and second legs, said first leg paralleling and being disposedadjacent said other end of the array, and said second leg extendingalong a side of the array to a position adjacent said one end of thearray, said water removing means including said troughs and the firstleg of the return trough being arranged for the gravitational overflowof the former into the latter, and said return trough having its legssloped so that water therein flows to said posi- 20. The combination ofclaim 19, including a water supply vessel in heat exchange relation withambient atmosphere, and means for moving water from the return trough tosaid vessel.

1. In packaging apparatus, the improvement comprising an elongatedtrough extending between charging and discharging stations adapted tocontain water, a boatlike mold disposed in said trough and adapted tofloat on water in the trough for movement between the stations, means atsaid charging station for depositing a quantity of the material to bepackaged into the mold when the latter is at the charging station, andmeans for moving the mold along the trough to the discharging station.2. The combination of claim 1, wherein said means for moving the moldcomprises means for moving water in the trough from the charging to thedischarging station.
 3. The combination of claim 2, wherein the meansfor moving the water includes means for receiving water from the troughadjacent the discharge station and for delivering water so received tothe trough adjacent the charging station.
 4. The combination of claim 2,wherein said means for moving the water includes means for receivingwater from the trough adjacent the discharge station, and meansinclusive of a pump for delivering water so received into the troughadjacent the charging end.
 5. The combination of claim 4, including asecond elongated trough having first and second portions that arerespectively relating closer to the discharge and charging stations ofthe first mentioned trough, said second trough being sloped downwardlyfrom the first to the second portion thereof whereby water therein willflow from the first to the second portion thereof, said first portion ofthe second trough being disposed at a height less than that of the firstmentioned trough at the discharge station of the latter, means foroverflowing water in the first mentioned trough that is above apredetermined depth at the discharge station into the first portion ofthe second trough, and with said pump being disposed to receive waterfrom the second portion of the second trough in an arrangement such thatthe mold can be removed from the first mentioned trough at the dischargestation, and placed in the first portion of the second trough for waterurged movement in the second trough to a position in the second portionof the latter in closer proximity to the charging station.
 6. Thecombination of claim 5, including a conveyor for moving a mold fromadjacent said position to a second position in relatively closerproximity to the charging station.
 7. The combination of claim 3,wherein said means for receiving and delivering water includes means forcooling the water prior to delivery thereof.
 8. The combination of claim3, including a water storage tank disposed at a height greater than thecharging station, whereby water can be delivered by gravity flow fromthe tank into the trough adjacent the charging station of the latter,and a pump for pumping received water into the tank.
 9. The combinationof claim 3, wherein received water is placed in direct heat exchangerelation with the atmosphere for cooling thereof prior to delivery intothe trough.
 10. The combination of claim 3, wherein received water isplaced in indirect heat exchange relation with the atmosphere forcooling thereof prior to delivery into the trough.
 11. Asphalt packagingapparatus comprising a plurality of elongated and generally paralleltroughs disposed in a generally rectangular array with each troughhaving one end at one end of the array and its other end at the otherend of the array, means for introducing water into each of the troughsat its said one end, means for removing water from the other ends of thetroughs, a plurality of boatlike molds adapted to float in said trougHsin heat exchange relation with water therein and to be moved by watermovement therein from the one end to the other end of each trough, andmeans for pouring a quantity of hot asphalt into said molds whenfloating at said one end of each of said troughs.
 12. The combination ofclaim 11, wherein the means for pouring includes an asphalt dispensingmanifold extending along said one end of the rectangular array, meansfor maintaining contents of the dispensing manifold at an elevatedtemperature suitable for dispensing asphalt therefrom, said asphaltdispensing manifold having a valved outlet above each of the troughsadjacent said one end of the troughs.
 13. The combination of claim 11,wherein the means for introducing water includes a common water supplyand each of said troughs having individually associated therewith avalve controlled means that is coupled to a water supply.
 14. Thecombination of claim 11, including an endless conveyor means adjacent toand parallel to said one end of the rectangular array for moving moldsfrom adjacent a corner of said array along a travel path adjacent saidone end of all the troughs.
 15. The combination of claim 14, includingan endless conveyor adjacent to and parallel to the other end of therectangular array for moving packaged asphalt from adjacent said otherends of all the troughs toward a single cargo handling location.
 16. Thecombination of claim 11, wherein the means for introducing water and themeans for removing water are operatively associated by means forreturning removed water to the water introducing means, whereby water isrecirculated through the troughs.
 17. The combination of claim 16,wherein the means for returning water includes means for cooling thewater.
 18. The combination of claim 16, wherein the means for returningwater includes an elongated generally L-shaped water return troughhaving first and second legs, said first leg paralleling and beingdisposed adjacent said other end of the array, and said second legextending along a side of the array to a position adjacent said one endof the array, said water removing means including said troughs and thefirst leg of the return trough being arranged for the gravitationaloverflow of the former into the latter, and said return trough havingits legs sloped so that water therein flows to said position, wherebyempty molds can be placed in the first leg of the return trough forwater urged movement in said return trough to said position.
 19. Thecombination of claim 18, including a conveyor means parallel to andadjacent said one end of the array for moving molds from adjacent saidposition along a path adjacent all said one end of the troughs.
 20. Thecombination of claim 19, including a water supply vessel in heatexchange relation with ambient atmosphere, and means for moving waterfrom the return trough to said vessel.